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Instructions Installation Operation Maintenance E50001-U229-A304-X-US00

Series 81000™ Controller

5 - 7.2kV Medium-Voltage Vacuum Contactors Types 96H35 and 97H35 (5kV) Types 96H37 and 97H37 (7.2kV) Power Transmission & Distribution

Hazardous voltages and high-speed moving parts. Will cause death, serious injury or property damage. Always de-energize and ground the equipment before maintenance. Read and understand this instruction manual before using equipment. Maintenance should be performed only by qualified personnel. The use of unauthorized parts in the repair of the equipment or tampering by unqualified personnel will result in dangerous conditions which will cause death, severe injury or equipment damage. Follow all safety instructions contained herein.

IMPORTANT The information contained herein is general in nature and not intended for specific application purposes. It does not relieve the user of responsibility to use sound practices in application, installation, operation, and maintenance of the equipment purchased. Siemens reserves the right to make changes in the specifications shown herein or to make improvements at any time without notice or obligations. Should a conflict arise between the general information contained in this publication and the contents of drawings or supplementary material or both, the latter shall take precedence.

QUALIFIED PERSON For the purpose of this manual and product labels, a qualified person is one who is familiar with the installation, construction, operation, or maintenance of the equipment and the hazards involved. In addition, this person has the following qualifications: (a) is trained and authorized to energize, de-energize, clear, ground, and tag circuits and equipment in accordance with established safety procedures. (b) is trained in the proper care and use of protective equipment such as rubber gloves, hard hat, safety glasses or face shields, flash clothing, etc., in accordance with established safety practices. (c) is trained in rendering first aid.

GENERAL These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met in connection with installation, operation, or maintenance. Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the local Siemens sales office. The contents of this instruction manual shall not become part of or modify any prior or existing agreement, commitment or relationship. The sales contract contains the entire obligation of Siemens Power Transmission & Distribution, Inc. The warranty contained in the contract between the parties is the sole warranty of Siemens Power Transmission & Distribution, Inc. Any statements contained herein do not create new warranties or modify the existing warranty.

Contents

Introduction and Safety . . . . . . . . . . . . . . . . . . . . . . . . 2 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Qualified Person . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Signal Words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Hazardous Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Field Service Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-6 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3 3TL8 Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4 Use of 96H3 or 97H3 Contactor in Other Cell Types . . .4 Service Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5 Control Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Application Considerations . . . . . . . . . . . . . . . . . . . . . . .5 Blown Fuse Trip Mechanism (Option) . . . . . . . . . . . . . . .5 Mechanically Latched Contactors (Option) . . . . . . . . . . .5 Surge Protection (Option) . . . . . . . . . . . . . . . . . . . . . . . .5 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Receiving Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8-12 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Site Preparation and Mounting . . . . . . . . . . . . . . . . . . . .8 Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Latched Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8 Pre-Energization Check . . . . . . . . . . . . . . . . . . . . . . . . . .9 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13-23 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13 Recommended Maintenance and Lubrication . . . . . . .13 Blown Fuse Trip Mechanism . . . . . . . . . . . . . . . . . . . . .14 Vacuum Contactor Inspection . . . . . . . . . . . . . . . . . . . .14 Main Contact Inspection . . . . . . . . . . . . . . . . . . . . . . . .15

Closing Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Latch Mechanism (Latched Contactor Only) . . . . . . . . .16 Mechanical Interlock Arm (97H3 only) . . . . . . . . . . . . .16 Fuse Clip Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Terminals and Joints . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Periodic Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Dielectric Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16 Recommended Torque . . . . . . . . . . . . . . . . . . . . . . . . . .16 Vacuum Interrupter Replacement Procedure . . . . . . . .17 Removing the Interrupter . . . . . . . . . . . . . . . . . . . . . . .17 Installing the New Interrupter . . . . . . . . . . . . . . . . . . . .18 Drive Connection and Adjustment . . . . . . . . . . . . . . . .19 Mechanical Latch Replacement . . . . . . . . . . . . . . . . . . .19 Main (Magnet) Coil Replacement . . . . . . . . . . . . . . . . .21 Auxiliary Switch Replacement . . . . . . . . . . . . . . . . . . . .22 Electronic Economizer Replacement . . . . . . . . . . . . . . .23 Maintenance After a Fault . . . . . . . . . . . . . . . . . . . . .25 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Terminals and Internal Conductors . . . . . . . . . . . . . . . .25 Overload Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Fuse Holders . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . .26-27 Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28-33

1

Introduction and Safety Introduction

Signal Words

The 96H3 and 97H3 families of Medium-Voltage Contactors are designed to meet all the applicable NEMA standards. Successful application and operation of this equipment depends as much upon proper installation and maintenance by the user as it does upon the careful design and fabrication by Siemens.

The signal words “Danger”, “Warning” and “Caution” used in this manual indicate the degree of hazard that may be encountered by the user. These words are defined as:

The purpose of this instruction manual is to assist the user in developing safe and efficient procedures for the installation, maintenance and use of the equipment. Contact the nearest Siemens representative if any additional information is desired.

Warning - Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. Caution - indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

Hazardous voltages

Hazardous Procedures

Will cause death, serious injury or property damage.

In addition to other procedures described in this manual as dangerous, user personnel must adhere to the following:

Always de-energize and ground the equipment before maintenance. Installation, operation, or maintenance should be performed only by qualified persons thoroughly familiar with the equipment, instruction manuals, and drawings. Read and understand this instruction manual before using the equipment.

1. Always work only on de-energized equipment. Always de-energize a contactor, and remove it from the equipment before performing any tests, maintenance or repair. 2. Always let an interlock device or safety mechanism perform its function without forcing or defeating the device.

Qualified Person

Field Service Operation

For the purpose of this manual a Qualified Person is one who is familiar with the installation, construction or operation of the equipment and the hazards involved. In addition, this person has the following qualifications:

Siemens can provide competent, well-trained Field Service Representatives to provide technical guidance and advisory assistance for the installation, overhaul, repair and maintenance of Siemens equipment, processes and systems. Contact regional service centers, sales offices or the factory for details, or telephone Siemens Field Services at 1-800-347-6659 (919-365-2200 outside the U.S.)

• Training and authorization to energize, de-energize, clear, ground and tag circuits and equipment in accordance with established safety practices. • Training in the proper care and use of protective equipment such as rubber gloves, hard hat, safety glasses, face shields, flash clothing, etc., in accordance with established safety procedures. • Training in rendering first aid.

2

Danger - Indicates an imminently hazardous situation which, if not avoided, will result in death or serious injury.

For medium-voltage customer service issues, contact Siemens at 1-800-347-6659 (919-365-2200 outside the U.S.)

General Description General construction. The Type 96H3 or 97H3 vacuum contactors each consists of: (1) a low-voltage section which contains the main coil drive and auxiliary contacts; (2) a medium-voltage section which houses the vacuum interrupter, and (3) a support structure which provides mounting for the power fuses, control transformer and primary fuses, and drawout attachments. Since interruption is accomplished completely within the vacuum interrupters, items such as arc chutes, blowout coils and pole plates are not required with vacuum contactors. Voltage surge suppressors are sometimes furnished at the controller load terminals to limit transient overvoltages caused by multiple reignitions which may occur due to the use of vacuum interrupters. For application guidelines, refer to the instruction manual for Series 81000 Controllers E50001-U229-A303-X-US00.

Siemens Type 96H3 and 97H3 vacuum contactors are provided for use in Series 81000™ medium-voltage controllers. These contactors provide the advantage of long mechanical and electrical life with low maintenance. They are suitable for loads of all types, including three-phase motors, transformers, capacitors and resistive loads. The overall dimensions of the vacuum contactor are 18 inches (457mm) wide by 27.5 inches (699mm) high by 23.87 inches (606mm) deep. The vacuum contactor with single or double barrel power fuses can be installed in Series 81000 Class E2 controllers of either one high (5kV or 7kV), two high (5kV or 7kV) or three high (5kV) Table 1. 96H3 or 97H3 Contactor Ratings

Interrupting Capacity Contactor Type

Maximum Voltage Rating

Enclosed Continuous Ampere Rating

Unfused Class E1 Controller (kA) Symmetrical

Fused Class E2 Controller (MVA)

Impulse Level (BIL) (kV)

96H35 97H35

5.0kV

360

5kA

200 @ 2.3kV 350 @ 4.0kV 400 @ 4.6kV

60

96H37 97H37

7.2kV

360

4.2kA

570 @ 6.6kV

60

Table 2. Maximum Motor Fuse and Transformer Fuse Rating 3 Phase Horsepower Rating at Utilization Voltage

Transformer Loads

2300V 4000-4600V 6600V Fused Maximum Maximum Maximum 3-Phase kVA Contactor Syn. Syn. Ind. Syn. Syn. Ind. Syn. Syn. Ind. Motor Transf. at Distribution Voltage Type Motors Motors Motors Motors Motors Motors Motors Motors Motors Fuse Fuse Rating Rating 0.8PF 1.0PF 0.8PF 1.0PF 0.8PF 1.0PF 2400V 4160V 4800V 6900V 96H35 97H35

1500

1750

1500

2500

3000

2500







24R

1500

2500

2500



450E

96H37 97H37













4000

5000

4000

24R







1500

200E

Table 3. Operating Data (Magnetically Held)

Table 4. Operating Data (Latched Type)

Rated Voltage Rated Current Permissible Switching Frequency Mechanical Life Electrical Life Closing Time Minimum Closing Command Duration Opening Time

7200V 400A (open) — 360A (enclosed) 1200/Hour 1,000,000 operations 250,000 operations 150 ms 300 ms 325 ± 75 ms (standard) (Fast dropout option ≤ 50 ms)

Permissible Switching Frequency Mechanical Life Control Voltage Options Available

60/Hour

Tripping Voltage

85% Rating DC

Tripping Power

500 W

Arcing Time Pick-Up Voltage AC or DC, Nominal Drop-Out Voltage AC or DC, Nominal Rated Control Voltage

10-20 ms 85% Rated (Hot) - 70% Rated (Cold) 74 ± 2V 120-240 V 50/60 Hz 125-250 VDC 600W 90W 2 NO - 2 NC (2 NO + 2 NC for purchaser’s use)

Coil Circuit Inrush Coil Circuit Holding Auxiliary Contact Arrangement Auxiliary Contact Rating

10A, 600V (NEMA Class A600)

100,000 Operations 24VDC, 32VDC, 48VDC, 125 VDC, 250VDC, 115VAC, 240VAC

3

General Description Molded Frame

Upper High-Voltage Terminal

Vacuum Interrupter

Flexible Conductor

Drive Arm For Aux. Contacts

Lower High-Voltage Terminal Closing Coil

Rotating Shaft Aux. Contacts

Electronic Economizer

Mounting Base

Figure 1. Construction of Type 3TL8 Contactor 3TL8 Contactor

Use of 96H3 or 97H3 Contactor in Other Cell Types

The 96H3 and 97H3 families of drawout contactors incorporate the Siemens Type 3TL8 contactor, mounted in a drawout carriage. The construction of the basic 3TL8 contactor is shown in Figure 1.

The types 96H3 and 97H3 contactors differ in the manner in which the interlocks are constructed and operate. Therefore, 96H3 and 97H3 contactors are not interchangeable with each other. Similarly, these contactors are not directly interchangeable with the earlier 90H3 contactors. Modifications necessary to allow use of a 96H3 or a 97H3 contactor in a 90H3, 93H3, or 94H3 cell are summarized in Table 5. Contactor Type 93H3 or 96H3

90H3

Power Cell (Compartment) Type

Cell modification kit 25-213-200-501 required. Mount per 25-154-488-424. Kit includes new interlock spring and replacement mechanical latch. Modified cell will allow use of either 90H3, 93H3, or 96H3 contactor.

93H3 or 96H3

––

94H3 or 97H3

Modification of contactor required. Remove cable interlock assembly from 93H3 or 96H3 contactor, and replace with new interlock lever to convert to 94H3/97H3 configuration. Cell interlock modification also required. Use modification kit 25-154-555-811, which includes parts needed for contactor as well as for cell. Mount per 25-213-213-411.

94H3 or 97H3 Cell modification kit 25-154-555-805 required. Mount per 25-213-213-405. Kit includes replacement interlock parts. Modified cell will no longer allow use of 90H3 contactor. Cell modification kit 25-154-555-804 required. Mount per 25-213-213-404. Kit includes replacement interlock parts. Modified cell will no longer allow use of 93H3 contactor.

Table 5. Modification Matrix for Use of 96H3/97H3 Contactor in 90H3/93H3/94H3/96H3/97H3 Cells

4

––

General Description Service Conditions

Blown Fuse Trip Mechanism (Option)

The 96H3 and 97H3 vacuum contactors should be used in the following conditions.

Contactors can be supplied with an anti-single phase trip mechanism which offers protection from single phasing due to a blown power fuse. Fused contactors equipped with the blown fuse trip mechanism are preadjusted at the factory so that the opening of one or more power fuses results in deenergizing the contactor coil, thus interrupting current to the load. When a power fuse blows, a plunger extends from the load end of the fuse which rotates the spring-loaded trip bar and releases a pre-compressed micro-switch on the side of the contactor. A contact on the micro-switch opens at this time and de-energizes the contactor magnet coil.

Table 6. Normal Service Conditions Altitude:

Less than 2,000 m (6600 ft) Above 2,000 m consult factory

Ambient Temperature:

-5oC min. to +40oC max. Average over a period of 24 hr shall not exceed +35oC

Relative Humidity:

45% min. to 85% max.

If the contactor is to be used in conditions other than those specified above, please consult Siemens. The location where the contactor is to be installed should be free from dust, corrosive gas and moisture. When it is to be used in a chemical plant or in outdoor enclosures, take necessary precautions against corrosion, water seepage and condensation. Control Voltage The drive unit for the closing coil assembly is installed in a cavity in the molded frame housing. The closing circuit can be operated by applying either AC or DC to this drive unit. The drive unit accepts any control voltage in the range of 120-250 volts, AC or DC. The optional latch trip circuit uses DC as standard. When a latched contactor is operated using AC power, it is recommended that a capacitor trip device be used. Application Considerations 1. Verify that the voltage and current applied is within the specified ratings. (See Tables 1 and 2) 2. The switching life of the vacuum interrupter is approximately 250,000 operations. The vacuum interrupter should be replaced after 250,000 operations. If the contactor is not protected by current limiting fuses, the vacuum interrupters should be replaced if they have interrupted fault currents at or near their maximum (unfused) interrupting rating.

Mechanically Latched Contactors (Option) Mechanically latched contactors are available which consist of a standard 96H3 or 97H3 contactor with the addition of a mechanical latch assembly. The mechanical latch holds the armature of the contactor closed against the magnet core after the contactor is energized (closed) and control power is removed. A pushbutton on the high voltage compartment door, when manually depressed, actuates the trip rod and trips the contactor by releasing the mechanical latch. Electrical trip with an internal solenoid is optionally available from the normal control transformer source or from a stored energy (capacitor) source which is charged from the normal control source. The stored energy source provides reliable trip power for a maximum delay of 5 minutes after loss of control power. Special trip circuits energized from remote power sources can be provided. The contactor latch is designed for DC control power. Standard control circuit options are available for 115V and 230 VAC trip circuits using rectifiers or rectifiers with capacitors to convert AC to DC to operate the mechanical latch. Refer to Tables 3 and 4 for latched contactor operating data. Refer to specific drawings supplied with the equipment for details on connection and operation. Surge Protection (Option)

3. When the contactor is applied to a capacitor load, be sure to use a space heater to keep humidity low. Be sure to use a heater adequately sized for the compartment in which the contactor is installed. The contactor should always be applied with a protective power fuse. 4. If the interrupter becomes dirty, simply clean it with a dry, lint-free cloth. For stubborn dirt on a vacuum interrupter, use a cloth and warm water and a small amount of mild liquid household detergent as a cleaning agent. Dry thoroughly using a lint-free cloth.

The 96H3 and 97H3 vacuum contactors are suitable for application without protection from surges related to switching with vacuum, except for jogging or inching duty with small (under 100HP) motors. For such applications, metal-oxide surge limiters should be specified. Regardless of the switching means employed, if the insulation integrity of the motor is suspect, such as for very old machines, it may be desirable to add surge protection for the machine, or to consider upgrading the machine to modern insulation standards.

5

General Description

9XH3

X 3 X XX X X X X X

Contactor Type 6 = 96H3 Contactor for use in 93H3 or 93H3 cells (cable interlock) 7 = 97H3 Contactor for use in 94H3 or 97H3 cells (lever interlock)

Contactor or Carriage Designation A = Drawout Contactor F = Fuse Carriage (for 720A Controller) T = Drawout Contactor with Anti-Single Phase Trip Bar

Insulation Voltage 5 = 5kV 7 = 7.2kV Number of Poles 3 = 3 Poles Interruption Capacity 1 = 5.0kA @ 5.0kV, 4.2kA @ 7.2kV 2 = 200 MVA 3 = 350 MVA 4 = 400 MVA 5 = 570 MVA Main Fuse Rating 00 = None 20 02 = 2R 25 03 = 3R 26 04 = 4R 27 06 = 6R 28 09 = 9R 29 12 = 12R 30 18 = 18R 31 24 = 24R 32 99 = Misc.

= = = = = = = = =

20E 25E 30E 40E 50E 65E 80E 100E 125E

33 34 35 36 37 39 40 41 42

= = = = = = = = =

150E 200E 250E 300E 325E 350E 375E 400E 450E

Table 7. Contactor Catalog Number System

6

Other Options (If Used) L = Latched Contactor w/Electrical Trip C = Latched Contactor w/Capacitor Trip S = Special Contactor, See Drawing

CPT Capacity in kVA 0 = No CPT 1 = 0.75kVA 2 = 1.5kVA 3 = 2.0kVA 4 = 2.5kVA 5 = 3.0kVA 6 = 3.25kVA 7 = Other CPT Secondary or Control Circuit Voltage A = 115VAC B = 230VAC C = 125VDC D = 250VDC E = Other N = None CPT Primary Voltage 0 = No CPT 2 = 2300V 60Hz 3 = 3300V 60Hz 4 = 4000V 60Hz 5 = 4600V 60Hz 6 = 3300V 50Hz 7 = 6600V 60Hz 8 = Special 9 = Other (Max. 7200V)

General Description Nomenclature The contactor configuration can be identified through the nomenclature description shown in Table 7. Upon receipt of this equipment, an immediate inspection should be made for any damage which may have occurred during shipment. The inspection should include examination of the packaging material and the contactor. Be sure to look for concealed damage and do not discard the packaging material. If damage is found, note damage on “Bill of Lading” prior to accepting receipt of the shipment, if possible. IMPORTANT: The way visible shipping damage is treated by the consignee prior to signing the delivery receipt can determine the outcome of the damage claim to be filed. Notification to the carrier within the 15 day limit on concealed damage is essential if loss resulting from unsettled claims is to be eliminated or minimized. A claim should be immediately filed with the carrier, and the Siemens sales office should be notified if damage or loss is discovered. A description of the damage and as much identification information as possible should accompany the claim. Handling For convenience and safety in lifting or moving the contactor, a lifting device similar to that shown in Figure 2 should be used. IMPORTANT: The lifting device is not intended to be used as a means of transporting the contactor in the raised position. The contactor should be transported with the lifting device in its lowered position. A crane or hoist can also be used to handle the contactor, if the lifting device is not available.

Figure 2. Use of Lift Device with 97H3 Contactor 7. Take care to avoid collisions with structures, other equipment, or personnel when moving the contactor. 8. Never lift a contactor above an area where personnel are located. Storage

If a forklift is utilized, the following precautions should be taken when moving contactors: 1. Keep the contactor in an upright position only. 2. Make sure the load is properly balanced on the forks. 3. Place protective material between the contactor and the forklift to prevent bending or scratching.

The contactor must be stored in a clean, dry, dust and condensation-free environment if it cannot be placed into service reasonably soon after receipt. Do not store equipment outdoors. A standard 75 watt light bulb, connected to burn continuously, should be placed near the lower portion of the contactor to prevent condensation.

4. Securely strap the contactor to the forklift to prevent shifting or tipping. 5. Excessive speeds and sudden starts, stops, and turns must be avoided when handling the contactor. 6. Lift the contactor only high enough to clear obstructions on the floor.

7

Installation Electrical Connections Hazardous voltages. Will cause death, serious injury, or property damage. Disconnect, ground, and lockout incoming power and control voltage sources before beginning work on this or any other electrical equipment. Installation should be performed only by qualified personnel.

Introduction Before performing any installation activities: • Test all power terminals to verify that incoming power has been disconnected. Use only approved high-voltage test equipment to check voltage on power terminals. Do not attempt to measure highvoltage (over 600 volts) with a volt-ohm meter. • Check all control and secondary circuit terminals with a voltmeter to make certain that all sources of incoming control and secondary voltage have been disconnected. • Connect safety grounds to power terminals after the system has been de-energized, and prior to working on the equipment. • Perform all disconnecting, grounding, and lockout operations in accordance with established safety procedures. • Follow the procedure outlined in the PreEnergization Check section of this manual before power is restored. Site Preparation and Mounting Installation shall be in accordance with the National Electrical Code (NFPA 70) and NEMA Standards. The contactor enclosure should be installed in a clean, dry, heated location with good ventilation. It should be readily accessible for cleaning and inspection and should be carefully set up and leveled on its supporting foundation and secured in place. All adjustments have been made at the factory before shipping and generally no change is required. See that all contact surfaces are clean and smooth, and that current-carrying parts are not damaged. * Megger is a registered trademark of Megger Group, Ltd.

8

Inspect all insulated wiring to see that no damage has occurred. Test the high-voltage wiring for possible grounds or short circuits. An AC dielectric test at 2.25 times the nominal system voltage plus 2000 volts, applied for one minute between phases and from all phases to ground is the preferred method. Be sure to disconnect any devices (control power transformer, etc.) from the circuit which could be damaged by the test voltage. If a hi-pot tester is not available, then a Megger* test at 1000 volts is a suitable second choice.

Hazardous voltages. Can cause death or serious injury. Dielectric or Megger testing should only be conducted by qualified personnel. Refer to instructions provided with the testing equipment for safety instructions.

Note: Do not use DC high potential testers incorporating half-wave rectification. These devices produce high peak voltages. These high voltages will produce X-ray radiation. These devices also show erroneous readings of leakage current when testing vacuum interrupters. Make sure that all current-carrying parts outside the contactor have adequate current-carrying capacity and are correctly insulated in accordance with the requirements of the National Electrical Code (NEC). All electrical connections should be made carefully per the wiring diagram furnished with the equipment. Tighten all lugs to recommended torque values (refer to Table 10). If crimp type terminals have been furnished, use only the crimping tools recommended by the manufacturer of the terminal. Latched Contactors An extension is required to extend 3.62” (91.9mm) from the auxiliary trip lever for a latched contactor used in bottom compartments. All latched contactors shipped in bottom compartment have an extension attached to the auxiliary trip lever perpendicular to the door. For contactors shipped in middle or top compartments, or shipped separately, the extensions are attached to the auxiliary trip lever and in parallel to the door. When contactors are shipped separately and are to be used in a bottom compartment, the extension must be assembled to the auxiliary trip lever per Figure 3.

Installation Pre-Energization Check 5º - 6º

5º - 6º Actuator

Trip Lever on Inside of Door

Hazardous voltages. Will cause death, serious personal injury or property damage.

0.125 From Contact Point to the Bottom of Lever

Extension Auxiliary Trip Lever

Figure 3. Latched Contactor Extension

Disconnect, lockout, and ground incoming power and control voltage sources before beginning work on this or any other electrical equipment. All pre-energization checks outlined in this instruction manual must be performed before the equipment is energized. This equipment should be energized by qualified personnel only.

1. Be sure all phase barriers are correctly installed. 2. Clean any excessive dust and dirt that may have accumulated if the contactor has been in storage. 3. Connect only test power and operate the contactor electrically several times. The contactor should pick up and seal cleanly at 85% to 110% of rated control voltage (See Operating Data, Table 3) 4. For latched type contactor, check that the latch correctly engages and trips when the close/trip signals are applied. Also, manually trip the contactor using the trip lever to verify proper operation. 5. Complete all Pre-Energization Checks in accordance with Series 81000 Controller Instruction Manual E50001-U229-A303-X-US00. The contactor may now be placed in service by connecting main incoming power. The contactor must be appropriately guarded or isolated before energizing the medium-voltage circuit. Refer to Series 81000 Controller Instruction Manual E50001-U229-A303-XUS00 for additional information. For typical control circuit diagrams see Figures 4, 5 and 6.

9

Installation

Test Switch Contact Development

RUN

LSI X1

X2

115V. or 230V. CPT

TEST

C CXFU

A

Push to Test

X C

B

X

C

X

RUN

12

L2

RL

TEST L1

X= Contacts Closed C

B

RSI

TFU

8

9

A

6

115V. or 230V. Test Power

Legend CPT . . . .Control Power Transformer CXFU . .Fuse for CPT Sec. LSI . . . . .Line Switch Interlock M . . . . . .Main Contactor MR . . . . .Master Relay M CC . . .Main Contactor Magnet Coil

START STOP

1

2

OL

3 MR MR

10 A

M

B

11

13

14 RL . . . . .High Voltage Light RSI . . . . .Racking Switch Interlock TFU . . . .Fuse for Test Power

MR

15

F A1

A2

DC Drive Unit 1

1

2

M CC M CC Additional Auxiliary Contacts M 84

G

M 83

H

12

43

I

13

M 44

J

14

K

15

M

21

22

L

16

32

M

17

31

N

18

19

Figure 4. Series 81000 Controller with Type 96H3 or 97H3 Magnetically-Held Contactor

10

2

D 13

Installation

Test Switch Contact Development

RUN

LSI X1

X2

115V. or 230V. CPT

TEST

A

C

Push to Test

CXFU

X C

B

X

C

X

12

L2

RL RUN

TEST L1

X= Contacts Closed C

B

RSI

TFU

8

9

A

6

115V. or 230V. Test Power LM

A1

A2

TX 43

Legend CPT . . . .Control Power Transformer CXFU . .Fuse for CPT Sec. LSI . . . . .Line Switch Interlock LM . . . . .Main Contactor (Latched Type) REC . . . .Rectifier RL . . . . .High Voltage Light RSI . . . . .Racking Switch Interlock T . . . . . .Trip Coil TFU . . . .Fuse for Test Power TX . . . . .Trip Aux. Relay LM CC . .Main Contactor Magnet Coil

44

TRIP

(+)

15

F

AC

Rec. -1

AC

(-)

TX

TX T

44

43 13

14

CLOSE 24

O

D 13

A1

DC Drive Unit 1

1

2

LM CC

A2 2

Mech. Trip

LM CC Additional Auxiliary Contacts LM 13

B

LM 14

A

5

84

G

4

12

LM 83

H

21

K

13

LM 22

L

16

32

M

17

31

N

18

19

Figure 5. Series 81000 Controller with Type 96H3 or 97H3 Contactor with Mechanical Latch, and Electrical Trip from AC Source

11

Installation

Test Switch Contact Development

RUN

115V. or 230V. CPT

LSI X1

X2

TEST

A

C

Push to Test

CXFU

X C

B

X

C

X

12

L2

RL RUN

TEST L1

X= Contacts Closed C

B

RSI

TFU

8

9

A

J3

115V. or 230V. Test Power

6 (+) AC

15 Legend CAP . . . .Capacitor CPT . . . .Control Power Transformer CXFU . .Fuse for CPT Sec. LSI . . . . .Line Switch Interlock LM . . . . .Main Contactor (Latched Type) Rb . . . . .Bleeding Resistor Rc . . . . .Charging Resistor REC . . . .Rectifier RL . . . . .High Voltage Light RSI . . . . .Racking Switch Interlock T . . . . . .Trip Coil TFU . . . .Fuse for Test Power LM CC . .Main Contactor Magnet Coil

AC

Rec. -1

19

Rc (-)

43 LM 44

F

A1

A2

J

TX TX

13

LM

14

CAP

E1

T 44 AC

Rb (+)

TRIP

CLOSE

REC -2

16 G

(-)

H 17

84 LM4 83

Maintain Contact If Used CLOSE 4

O

D A1

1

LM 13

B

LM 14

A

5

84

G

4

LM 83

H

12

21

K

13

LM 22

L

16

32

M

17

1

2

LM CC

Additional Auxiliary Contacts

18

31

A2

DC Drive Unit

13

2

Mech. Trip

LM CC

N

19

Figure 6. Series 81000 Controller with Type 96H3 or 97H3 Contactor with Mechanical Latch, and Electrical Trip from AC Capacitor Source

12

Maintenance Hazardous voltages. Will cause death, serious personal injury, or property damage. Disconnect, lockout, and ground incoming power and control voltage sources before beginning work on this or any other electrical equipment. Maintenance should be performed only by qualified personnel.

Note: A preventive maintenance program is not intended to cover reconditioning or major repair, but should be designed to reveal, if possible, the need for such actions in time to prevent malfunctions during operation. Recommended Maintenance and Lubrication Periodic maintenance and lubrication should include all of the tasks shown in Table 8. Recommended procedures for each of the listed tasks are provided in this section of the manual, or in the references cited in this manual.

Introduction • •



Before performing any maintenance: Test all power terminals to verify that incoming power has been disconnected. Use only approved high-voltage test equipment to check voltage on power terminals. Do not attempt to measure highvoltage (over 600 volts) with a volt-ohm meter. Check all control and secondary circuit terminals with a voltmeter to make certain that all sources of incoming control and secondary voltage have been disconnected.



Connect safety grounds to power terminals after the system has been de-energized, and prior to working on the equipment.



Perform all disconnecting, grounding, and lockout operations in accordance with established safety procedures.



Follow the procedure outlined in the PreEnergization Check section of this manual before power is restored.

General For the safety of maintenance personnel as well as others who might be exposed to hazards associated with maintenance activities, the safety related work practices of NFPA 70E should always be followed when working on electrical equipment. Maintenance personnel should be trained in the safety practices, procedures and requirements that pertain to their respective job assignments. This manual should be reviewed and retained in a location readily accessible for reference during maintenance of this equipment. The user must establish a periodic maintenance program to ensure trouble-free and safe operation. The frequency of inspection, periodic cleaning and preventive maintenance will depend upon the operating conditions. NFPA Publication 70B “Electrical Equipment Maintenance” may be used as a guide to establish such a program.

Use of unauthorized parts in the repair of the equipment, altering of the design, or tampering by unqualified personnel can result in dangerous conditions, which could cause death, serious injury, or equipment damage. Follow all safety instructions contained herein.

Failure to properly maintain the equipment can result in death, serious personal injury, or product failure, and can prevent successful functioning of connected apparatus. The instructions contained herein should be carefully reviewed, understood, and followed. The maintenance tasks in Table 8 must be performed regularly.

• • • • • • • • • • •

Blown Fuse Trip Mechanism Checks Vacuum Contactor Inspection Main Contacts Inspection Closing Coil Check Latch Mechanism Check Mechanical Interlock Checks Fuse Clip Inspection Check of Terminals and Joints Periodic Cleaning Dielectric Test Maintenance Tasks in Manual for Series 81000 Controllers, E50001-U229-A303-X-US00

Table 8. Maintenance Tasks Maintenance of the vacuum contactor should only be performed with the contactor de-energized and withdrawn from the controller compartment. In the case where a vacuum interrupter must be replaced, control power is required to close the contactor during the “Operation Check”. The list of tasks in Table 8 does not represent an exhaustive survey of maintenance steps necessary to ensure safe operation of the equipment. Particular applications may require further procedures. Should further information be desired or should particular problems arise which are not covered sufficiently for the Purchaser’s purposes, the matter should be referred to the local Siemens sales office.

Hazardous voltage. Will cause death, serious personal injury, or property damage. Always de-energize and ground the equipment before performing maintenance.

13

Maintenance Blown Fuse Trip Mechanism IMPORTANT: Use of the trip mechanism with fuses other than Siemens type FM (for up to 5080 volts) or A720R (for up to 7200 volts) motor fuses can result in failure of the trip bar to operate. After the trip mechanism has operated, or if any of the power fuses have been removed or replaced, the following checks and adjustments must be performed. Support Tray

Plunger

Pushrod

Locknut Machine Screw

1

Switch Contacts Close

2 4 3

Figure 8. Adjustment of Trip Mechanism in Deactivated Position

5

Stop Insert 3/16” (4.8mm) Shim

Figure 7. Adjustment of the Plunger

Direction of Trip Bar Rotation

1. All fuses must be installed in clips with load side of fuse resting on support tray as shown in Figure 7. Plunger end of fuse must be facing forward, away from disconnect fingers on contactor. 2. With the trip bar in its normal spring return (deactivated position), the trip bar should rest against the stop screw on the right hand contactor side plate as shown in Figure 7. The trip bar must be held in this position while performing adjustments 3 and 4. â–²

4. Referring to Figure 8, loosen the machine screw which threads into the pushrod and adjust outward (lengthen) until the micro-switch contacts just close. Then adjust outward one additional full turn and tighten the locknut.

A â–²

3. Adjust each of the three plunger assemblies shown in Figure 7 to obtain a 1/16” (1.6mm) gap between the plunger (1) and the end of the corresponding fuse as follows: Insert a 1/16” (1.6mm) shim between the end of the fuse and the plunger (1). Loosen locknut (2) and turn adjusting screw (3) until there is no gap between stop nut (4) and trip bar (5). Retighten lock nut (2).

Figure 9. Operational Check of Trip Mechanism Vacuum Contactor Inspection The inspections listed in Table 9 are recommended for the vacuum contactor, whether mounted on a drawout carriage or mounted in a fixed location inside the controller enclosure.

Hazardous voltage.

5. Referring to Figure 9, insert a 3/16” (4.8mm) thick shim between one of the three plungers and the adjacent fuse, rotating the trip bar in the direction shown. The microswitch contacts should open at this point. If they do not, loosen the locknut and adjust the machine screw to shorten dimension “A” slightly until the switch contacts open, then retighten the locknut.

14

Will cause death, serious injury, or property damage. Always de-energize and ground the equipment before performing maintenance.

Maintenance Table 9. Vacuum Contactor Inspection Checklist Parts to be inspected

Inspection Item

Cracks

Discoloration

Contamination

Rust





Vacuum Interrupter (Notes 1 & 3) Main Circuit

Movable Conductor



Upper & Lower Terminals Molded Housing Mechanism Section

Insulation Flange Bearing

• •

Latch Mechanism (Note 2) Mechanical Interlock Check (97H3 Only)

Insulated Wire Notes:



• •

Visual Check Once a Year or Every 20,000 Operations



• • •

• •

• •





Bolts and Nuts Others

Inspection Intervals





Trip Coil

Interlock Bolt And Interlock Arm

Incomplete Vibrating Operation Sound



Armature and Core

Roller

Loose Parts





Closing Coil Electromagnet

• • •

Wear



1. The life expectancy of the electrical parts (vacuum interrupter, auxiliary switch) is 250,000 operations. 2. The life expectancy of the latch mechanism for latched contactors is 100,000 operations. 3. When the contactor is not protected by current limiting fuses, the vacuum interrupters should be replaced if they have interrupted fault currents at or near their maximum (unfused) interrupting rating.

High Potential tests employ hazardous voltages.

Note: Do not use DC high potential testers incorporating half-wave rectification. These devices produce high peak voltages.

Will cause death or serious injury. Follow safe procedures. Exclude unnecessary personnel. Use safety barriers. Keep away from the equipment during application of test voltages. Dielectric testing should be conducted only by qualified personnel. Refer to dielectric test equipment instructions for safety instructions.

Vacuum interrupters may emit X-radiation. Can cause serious injury. X-rays can be produced when a high-voltage is placed across the open contacts of a vacuum interrupter. Keep personnel at least three (3) feet from any vacuum interrupter during dielectric tests.

These high voltages will produce X-ray radiation. These devices also show erroneous readings of leakage current when testing vacuum interrupters. Main Contact Inspection 1. Check the upper and lower flanges and interrupter shaft for signs of contamination or corrosion. If there is contamination, use a clean cloth with warm water and a small amount of liquid household detergent as a cleaning agent. Dry thoroughly using a lint-free cloth. If there is corrosion, replace with a new interrupter. 2. With the vacuum interrupter closed, check the amount of main contact wear in the vacuum interrupter. Observe the erosion mark on the lower moving stem of the interrupter. This mark should be visible with the contactor closed. If the mark is not visible, the allowable contact wear has been exceeded, and the interrupter must be replaced

15

Maintenance 3. Check the vacuum interrupter for integrity of the vacuum. With the contactor open, apply 18kV AC between the upper and lower terminals for one minute. If the interrupter withstands this test, it is acceptable. If voltage breakdown occurs, the interrupter must be replaced.

Fuse Clip Inspection Closely examine fuse clips. If there is any sign of overheating or looseness, check the spring pressure or tightness of clamps. Replace the fuse clips if the spring pressure compares unfavorably with that of other similar fuse clips. Make sure that fuses are completely inserted.

Hazardous voltage. Will cause death, serious personal injury, or property damage. Always de-energize and ground the equipment before performing maintenance.

Closing Coil Check the main closing coils for signs of discoloration. Discoloration and/or burnt insulation indicates that overheating has occurred, and replacement of the magnet coils is necessary. Latch Mechanism (Latched Contactor Only) Check that the holding latch reliably engages. (To manually close the contactor, hold the central area of the rotating shaft with a wrench and operate.) Check the condition of the latch roller. It should be smooth. Mechanical Interlock Arm (97H3 only) Check the height of the interlock arm bolt head as shown in Figure 10, and lubricate the bolt head once per year or every 20,000 operations. Lubricant used should be Siemens contact lubricant, part no. 15-172-791-233 or Anderol 732, part no. 15-172-816-058. NOTE: Slight wear of the bolt head is normal. If replacement of the interlock bolt is necessary, do not replace with a standard bolt of the same size. Use only replacement bolt 25-154488-155 available from Siemens. Stainless Steel Interlock Bolt

Terminals and Joints If joints or terminations appear too badly discolored, corroded or pitted, or show evidence of having been subjected to high temperature, the parts should be disassembled and replaced or cleaned. Examine all wire or cable connections for evidence of looseness or overheating. Re-torque if necessary. If major discoloration or cable damage is apparent, replace the damaged parts. Periodic Cleaning Accumulation of dust and foreign material such as coal dust, cement dust, or lamp black must be removed from the contactor and all surfaces must be wiped clean at regular intervals. Dirty, wet or contaminated parts should be replaced unless they can be cleaned effectively. Dust can collect moisture, causing voltage breakdown. Do not use compressed air as it will only redistribute contaminants on other surfaces, and may damage delicate parts. Dielectric Test Perform dielectric tests as discussed under “Electrical Connections” in the Installation section of this manual. Recommended Torque When making bolted assemblies, the following considerations should be generally followed. The recommended torque is determined by the size of hardware used. Refer to Table 10. 1. Metal-to-Metal - Apply standard torque as listed. 2. Metal-to-Insert molded in compound part - Apply approximately 2/3 of standard torque.

(Off Position)

3. Compound-to-Insert molded in compound part Apply approximately 1/2 of standard torque. 10.84

+0.00 -0.015

4. Compound-to-Compound - Apply approximately 1/2 of standard torque.

Floor (Bottom of Wheel) Adjustment of Mechanical Interlock Arm Bolt Height

16

Figure 10. Adjustment of Mechanical Interlock Arm Bolt Height

Maintenance Thread Size

Standard Torque Metal-to-Metal (in-lbs/Nm)

2/3 Standard Torque Metal-to-Insert (in-lbs/Nm)

1/2 Standard Torque Compound-to-Insert (in-lbs/Nm)

1/2 Standard Torque Compound-to-Compound (in-lbs/Nm)

8-32

14-20/1.6-2.3

10-14/1.0-1.6

7-10/0.8-1.2

7-10/0.8-1.2

10-32

20-30/2.3-3.4

13-20/1.6-2.3

10-15/1.2-1.8

10-15/1.2-1.8

1/4-20

40-60/4.5-6.8

26-40/3.2-4.5

20-30/2.3-3.4

20-30/2.3-3.4

5/16-18

168-228/19-25.8

110-150/12.4-17

84-114/9.5-13

84-114/9.5-13

3/8-16

240-360/27-41

160-240/18-27

120-180/13.5-20.5

120-180/13.5-20.5

1/2-13

480-600/54-68

320-400/36-45

240-300/27-34

240-300/27-34

Table 10. Recommended Torque Values Vacuum Interrupter Replacement Procedure When a vacuum interrupter has reached a specified life (250,000 operations) or when it is damaged, it is recommended that it be replaced. If the contactor is not protected by current limiting fuses, the vacuum interrupters should be replaced if they have interrupted fault currents at or near their maximum (unfused) interrupting rating. The replacement vacuum interrupter kit (serial no. 31670936 and up) consists of a vacuum interrupter (4.1), a flexible shunt connector (5), contact washers (4.3.1, 5.3 and 6.1), and an adjusting tool. The replacement vacuum interrupter kit (up to serial no. 31670935) consists of a vacuum interrupter (4.1), flexible shunt connector and insulator assembly as well as washer (4.4.4), and spring (4.4.3), spacer tube (4.4.5), washer (4.4.6), lockwasher (4.4.7), nut (4.4.2), contact washers (6.1 and 5.3), and an adjusting tool. The replacement of vacuum interrupters should be performed as follows:

2. Loosen and remove the M8 nut (4.4.2), holding the movable contact (4.1.1) of the vacuum interrupter with an open end 17mm wrench to avoid damage to the interrupter bellows. 3. Remove two M5 hex head bolts (4.2.1) and remove latch (4.2.3). 4. Loosen and remove M8 hex head bolt (6.2) of upper terminal. 5. Remove vacuum interrupter and attached components from the contactor housing. 6. Loosen locknut (4.3.2), holding the movable contact (4.1.1) of the vacuum interrupter with an open end 17mm wrench to avoid damage to the interrupter bellows. 7. Unscrew the insulator (4.4) from the movable contact (4.1.1). All of the parts removed should be retained, as they will be reused in the new assembly, except for the following items: vacuum interrupter (4.1), flexible shunt connector (5), contact washers (6.1, 5.3 and 4.3.1), and lockwasher (4.4.7). Removing the Interrupter (Up to serial no 31670935) 1. (Refer to Figure 11.) Loosen the M8 hex head bolt (5.1) which secures the flexible shunt connection to the contactor housing, and remove.

Hazardous voltages. Will cause death or serious injury. Before replacing vacuum interrupters, remove the contactor from the controller compartment to ensure that all high-voltage sources are disconnected. Low-voltage test power is required during the reinstallation of new vacuum interrupters, so exercise caution.

Removing the Interrupter (Serial no. 31670936 and up) 1. (Refer to Figure 11.) Loosen the M8 hex head bolt (5.1) which secures the flexible shunt connection to the contactor housing, and remove.

2. Loosen and remove the M8 nut (4.4.1), holding the movable contact (4.1.1) of the vacuum interrupter with an open end 17mm wrench to avoid damage to the interrupter bellows. 3. Loosen and remove the M8 nut (4.4.2), while continuing to hold the movable contact (4.1.1) of the vacuum interrupter to prevent bellows damage. 4. Remove two M5 hex head bolts (4.2.1) and remove latch (4.2.3). 5. Loosen and remove M8 hex head bolt (6.2) of upper terminal. 6. Remove vacuum interrupter and attached components from the contactor housing. Retain following parts for reuse: bolts (6.2, 5.1 and 4.2.1), washers (4.2.2 and 5.2), nut (5.4) and latch (4.2.3).

17

Maintenance 6.2 6.1 1 6

4

33

4.3

4.4.2

T 4.2.4

D

4.4.1

3 4

4.2.1

5.1

4.2.2

5.2

4.2.3

5

Detail “A”

5.3 4.1.1 5.4 4.3.1 4.4 4.4.4 4.4.5 4.4.3 4.4.6

4.3.2

4.4.7 3 4.4.2 See Detail “A” For Serial No. Up To 31670935.

T

D

1 . . . . . .Contactor Housing 3 . . . . . .Drive Lever 4.1 . . . . .Vacuum Interrupter 4.1.1 . . .Movable Contact 4.2.1 . . .Hex Head Bolt (M5) 4.2.2 . . .Washer 4.2.3 . . .Latch 4.2.4 . . .Bearing 4.3.1 . . .Contact Washer 4.3.2 . . .Nut 4.4 . . . . .Insulator 4.4.1 . . .Locknut 4.4.2 . . .Nut 4.4.3 . . .Compression Spring 4.4.4 . . .Washer 4.4.5 . . .Spacer Tube 4.4.6 . . .Washer 4.4.7 . . .Lock Washer 5 . . . . . .Flexible Shunt Connector 5.1 . . . . .Hex Head Bolt (M5) 5.2 . . . . .Washer 5.3 . . . . .Contact Washer 5.4 . . . . .Nut 6 . . . . . .Upper Terminal 6.1 . . . . .Contact Washer 6.2 . . . . .Hex Head Bolt (M5)

Figure 11. Vacuum Interrupter Removal and Installation Installing the New Interrupter (Serial No. 31670936 & up) 1. (Refer to Figures 11 and 12) Screw locknut (4.3.2) and contact washer (4.3.1) onto insulator (4.4), slip flexible shunt connector (5) onto articulated bolt on the upper end of the insulator (4.4), slip bearing (4.2.4) onto movable contact (4.1.1) of vacuum interrupter (4.1). 2. Screw vacuum interrupter (4.1) onto articulated bolt on the upper end of the insulator (4.4). 3. Preset assembly to size (16 to 16.5mm) as shown in Figure 12, and secure it in correct adjustment using nut (4.3.2). Do not fully tighten nut (4.3.2) at this time. Nut (4.3.2) will be fully tightened in final position during the “Drive Connection and Adjustment” procedure. 4. Slip washer (4.4.4), spacer tube (4.4.5) and compression spring (4.4.3) onto lower articulated bolt of insulator (4.4)

18

5. Insert assembly into contactor housing (1), while passing lower articulated bolt through drive lever (3) and flexible shunt connector (5) through the opening in the rear of the housing (1). 6. Install latch (4.2.3) with hex head bolt M5 (4.2.1) and washer (4.2.2). 7. Secure vacuum interrupter (4.1) to the upper terminal (6), using hex head bolt M8 (6.2) and contact washer (6.1). 8. Secure flexible shunt connector (5) to housing using hex head bolt M8 (5.1), washer (5.2), nut (5.4) & contact washer (5.3). Torque to 10-14 Nm (88-124 in-lbs.). Installing the New Interrupter (Up to Serial No. 31670935) Follow the procedure in the preceding section, steps 4-8. Steps 1-3 are not required as the replacement kit includes a preset assembly comprised of the vacuum interrupter (4.1), flexible shunt connector (5), and insulator (4.4).

Maintenance 0.63-0.65” (16.0-16.5mm)

Hazardous voltage. Will cause death, serious injury, or property damage. Always de-energize and ground the equipment before performing maintenance.

4.3.1 4.2.4

Mechanical Latch Replacement 4.4

4.3.2

4.1.1

4.1

Can cause death or personal injury.

The mechanical latch is designed for operation from a DC control power source, or from a rectified AC source, or from a capacitor energy storage device supplying DC energy from a rectified AC source. To replace the mechanical latch, remove the drawout contactor carriage from the controller enclosure, and disconnect all sources of power. Remove the auxiliary trip lever (see Figure 3) to identify auxiliary trip lever components. The installation procedure for the replacement mechanical latch is as follows (refer to Figure 13 and Figure 14): 1. For units with AC latching coil, attach the rectifier module (9) to the thrust plate (2) using two M3 x 20 screws (9.1) tightened to 4.5-6.0 in-lbs (0.5-0.7 Nm). For DC latching coil, skip this step.

Adjustment of the connection from the lower end of the insulator (4.4) to the drive arm (3) requires that the contactor main coils be energized at rated control power.

2. Attach latching coil (1.1) and magnet core (1.2) to thrust plate (2) with M6 x 35 screw (1.3). Torque to 62-79 in-lbs (7- 9Nm).

Properly shield any energized parts so that they cannot be touched.

3. Attach latch stop (3) to drive lever (4) with two M5 x 30 screws (4.1). Torque to 48-57 in-lbs (5.5-6.5 Nm).

5

4.1 . . . . .Vacuum Interrupter 4.1.1 . . .Movable Contact 4.2.4 . . .Bearing 4.3.1 . . .Washer

4.3.2 . . .Nut 4.4 . . . . .Insulator 5 . . . . . .Flexible Shunt Connector

Figure 12. Adjusting of Insulator to Flexible Shunt Distance

Hazardous voltage.

4. Insert compression spring (5) into magnet core (1.2). Drive Connection and Adjustment (Refer to Figure 11) 1. From the rear of the contactor, install washers (4.4.6, 4.4.7) and nut (4.4.2) onto the articulated bolt on the lower end of the insulator (4.4). 2. Energize contactor at rated control power. Tighten nut (4.4.2) and torque to 13-17 Nm (114-150 inlbs) while holding the movable contact (4.1.1) of vacuum interrupter with an open end 17mm wrench to avoid damage to the interrupter bellows. 3. Tighten bolt (6.2) and torque to 13-17 Nm (114150 in-lbs) to the upper terminal. 4. Insert adjusting handle between drive lever (3) and washer (4.4.6) and adjust insulator (4.4) so that the gap between drive lever (3) and washer (4.4.6) is the same as the adjusting handle. Secure the insulator (4.4) by tightening the nut (4.3.2) to 1317 Nm (114-150 in-lbs) while holding the movable contact (4.1.1) of vacuum interrupter with an open end 17mm wrench to avoid damage to the interrupter bellows. 5. Remove the adjusting handle. 6. Using control power, operate the contactor on and off approximately 20 times to confirm normal operation.

5. Attach the frame and latch assembly (6) to the thrust plate (2) with four M5 x 16 screws (6.1). 6. To continue the installation, the contactor must be closed. This requires application of control power to the main coil. Use appropriate precautions to avoid injury or shock when control power is applied to the contactor. 7. Apply control power and switch the contactor to the closed (ON) position. 8. While the contactor is closed, insert a spacer (A) between the magnet plate (8.9) and the stop (B), as shown in Figure 14. The spacer is made of insulating material, and is approximately 10.5mm x 25mm x 180mm. 9. After the spacer has been inserted, switch the control power off. The spacer should maintain the contactor in the closed (ON) position. 10. Insert the adjusting plate (7) 0.2mm thick between the latch stop (3) and the latching pin (6.3). 11. Tighten the four M5 x 16 screws which fasten the frame and latch assembly (6) to the thrust plate (2). Torque to 48- 57 in-lbs (5.5-6.5 Nm). 12. Remove the adjusting plate (7). 13. Attach the control leads (1.4) to the correct terminals in accordance with the schematic diagram for the controller.

19

Maintenance 4

4.1

1.4mm (0.055 in.)

3 7.4 6.3

7 5 1.1 + 1.2 1.3

7.1 6.2 7.3

2 6

6.1

7.2 9

9.1 7.1

1.4

factory. Verify this dimension if contactor does not properly latch. Adjust actuator or auxiliary trip lever mounting location as needed. See Figure 3 to identify actuator, auxiliary trip lever, and other latch components. If this condition is satisfied, next, mechanically (manually) operate the actuator and verify that the contactor opens. Repeat this sequence of tests approximately 20 times to verify correct operation. 16. (Electrical trials) Reapply control power to the main coil to close the contactor. The mechanical latch should correctly latch and hold the contactor in the closed (ON) position after control power is removed from the main coil. If this condition is satisfied, next, apply the correct control power voltage for the mechanical latch trip coil (often different from the main coil control power voltage). Control power should be applied to the mechanical latch trip coil for at least 0.1 second, but not for longer than one second, or damage to the mechanical latch trip coil will result. Verify that the contactor opens when the mechanical latch is operated electrically. Repeat this sequence of tests approximately 20 times to verify correct operation.

6.3 6.1

1.1 . . .Latching Coil 1.2 . . .Magnet Core 1.3 . . .M6 x 35 Screw 1.4 . . .Latching Oil Leads 2 . . . .Thrust Plate 3 . . . .Latch Stop 4 . . . .Drive Lever 4.1 . . .M5 x 16 Screw 5 . . . .Compression Spring 6 . . . .Frame 6.1 . . .M5 x 16 Screw

7.3

6.2 . . .Latch 6.3 . . .Latch Pin 7 . . . .Adjusting Plate 7.1 . . .Actuator 7.2 . . .Actuator Support 7.3 . . .Delatching (trip) Lever 7.4 . . .Return Spring 9 . . . .Rectifier Module 3AX1525-OF 9.1 . . .M3 x 20 Screw

Spacer (A)

Magnet Plate (8.9)

Stop (B)

Figure 13. Mechanical Latch Installation 8.2.1 Washer

14. Attach the auxiliary trip lever. Adjust the location of the auxiliary trip lever so that it is touching the actuator but not pressing it in. Apply a thin coat of lubricant (Siemens contact lubricant, part no. 15172-791-233 or Anderol 732, part no. 15-172-816058) to the lever on the door where it meets the auxiliary trip lever. 15. (Mechanical trials) Reapply control power to the main coil to close the contactor. The mechanical latch should correctly latch and hold the contactor in the closed (ON) position after control power is removed from the main coil. A gap of 1.4mm (0.055 in) between delatching lever (7.3) and return spring (7.4) holding pin is preset at the

20

10.5mm

8.2 Mounting Bolts

2 Mounting base

Figure 14. Use of Spacer to Maintain Contactor Closed Position During Mechanical Latch Installation

Hazardous voltage. Will cause death, serious personal injury, or property damage. Always de-energize and ground the equipment before performing maintenance.

Maintenance Main (Magnet) Coil Replacement The magnet coil configuration employs a pair of magnet coils for each contactor. If it should become necessary to replace either of the magnet coils, replace both coils as a set. To replace the magnet coils, remove the drawout contactor carriage from the controller enclosure, and disconnect all sources of power. For non-drawout type contactors, disconnect and ground all sources of power, and remove the contactor from the enclosure. The replacement procedure is as follows (refer to Figure 14 and Figure 15) 1. (Removal of the magnet coils) Disconnect the leads of the magnet coils (8.1). 2. Remove the mounting bolts (8.2) which secure the magnet system (8) to the contactor mounting base (2). (Note: On early model drawout contactors, holes to allow access to the mounting bolts (8.2) are not provided. If access holes are not present, contact Siemens Field Service for assistance in replacing main magnet coils).

8. Note: The washer (8.8) mounted between the magnet core (8.6) and the magnet angle (8.4) is needed for installing the new magnet coil. There is one washer (8.8) per magnet coil. 9. The magnet core (8.6) is also to be reused. 10. Washers (8.3.1), (8.2.1), and (8.5.1) should be discarded and replaced with the new washers in the replacement magnet coil kit. 11. (Replacing the magnet coils) Install the new magnet coils (8.1), reversing the action in the previous step. Install each magnet coil over the magnet core (8.6) on the magnet angle (8.4), using bolt (8.5), new washer (8.5.1), and washer (8.8). Torque to 157-192 in-lbs (18- 22 Nm). 12. Align the magnet coils (8.1) into correct position so that the magnet core (8.6) is free to move, and secure the magnet coils (8.1) in position using plate (7). Torque to 39- 48 in-lbs (4.5-5.5 Nm). 13. Install bolts (8.3) with new washers (8.3.1). Torque to 157-192 in-lbs (18-22 Nm).

3. Remove the magnet system (8) from the contactor by sliding the assembly out the rear of the contactor.

14. Slide the magnet system (8) into the contactor from the rear.

4. Do not loosen or adjust items 8.10, 8.11, 8.12, or 8.13.

6. Loosen, but do not remove, plate (8.7).

15. Secure the magnet system (8) to the contactor mounting base (2) using bolts (8.2) and new washers (8.2.1). Tighten loosely, but allow some movement between the magnet system (8) and the contactor mounting base (2).

7. Remove the mounting bolt (8.5) at the rear side of the magnet angle (8.4).

16. Connect the leads from the new magnet coils (8.1) to the correct terminals on the contactor.

5. Remove the bolts (8.3) at the rear side of the magnet angle (8.4).

8.1

8.7

8.8

8.1

8.13 8.10

8.3 8.3.1

8.6

8.5 8.5.1 8.4 8.11

8.1 8.1

8.4

8 . . . . . .Magnet System (Fig. 14) 8.1 . . . .Magnet Coil 8.2 . . . .Bolt 8.2.1 . . .Washer 8.3 . . . .Bolt 8.3.1 . . .Washer 8.4 . . . .Magnet Angle 8.5 . . . .Bolt 8.5.1 . . .Washer

8.12

8.6 . . . .Magnet Core 8.7 . . . .Plate 8.8 . . . .Washer 8.9 . . . .Magnet Plate (Fig. 14) 8.10 . . .Spring Retainer 8.11 . . .Nut 8.12 . . .Bolt 8.13 . . .Compression Spring

Figure 15. Main Magnet Coil Replacement

21

Maintenance 17. To continue the installation, the contactor must be closed. This requires application of control power to the main coil. Use appropriate precautions to avoid injury or shock when control power is applied to the contactor. 18. (Alignment) Apply control power and switch the contactor to the closed (ON) position. The contactor should close correctly, and the closing process will cause the magnet system (8) to properly align with the magnet plate (8.9). 19. While the contactor is closed, torque the mounting bolts (8.2) to 157-192 in-lbs (18-22 Nm). While tightening the mounting bolts, assure that proper alignment between the magnet system (8) and the magnet plate (8.9) is maintained. 20. (Electrical trials) Apply control power and switch the contactor to the closed (ON) position. The contactor should close correctly and without unusual hesitation. Verify that the contactor opens when the control power is removed. Repeat this test approximately 20 times to verify correct operation

Be sure that the wires are attached to the correct terminals of the correct auxiliary switch block. 6. When all wires are properly secured, slide the auxiliary switch blocks with the wires attached into the proper location on the contactor drawout carriage, and align the auxiliary switch blocks to the mounting holes in the contactor housing (1). 7. Install lower auxiliary switch block (10.2) to the lower position on the contactor housing (1) using M3 x 35 screws. To install one of the screws, it will be necessary to rotate the actuator arm (7). 8. Install upper auxiliary switch block (10.1) to the upper position on the contactor housing (1) using M3 x 35 screws. 9. Reposition the actuator arm (7) and secure it to the shaft with screw (3), and torque to 5.5-6.5 Nm (96114 in-lbs). 10. To continue the installation, the contactor must be closed. This requires application of control power to the main coil. Use appropriate precautions to avoid injury or shock when control power is applied to the contactor.

Hazardous voltage. Will cause death, serious injury, or property damage. Always de-energize and ground the equipment before performing maintenance. 1

Auxiliary Switch Replacement To replace the auxiliary switch blocks, remove the drawout contactor carriage from the controller enclosure, and disconnect all sources of power. The procedure for replacement of auxiliary switch blocks is as follows (refer to Figure 16): 1. Remove screw (3) from the actuator arm, so that the arm is free to rotate.

7 3 10.1

2. Remove the screws which secure the auxiliary switch blocks to the contactor housing (1). There are four screws. The drawout contactor carriage side barrier has holes to allow for access to these screws without major disassembly of the contactor carriage. Three of the screws can be accessed directly, while the fourth screw can be accessed by rotating the actuator arm (7). 3. Slide the auxiliary switch blocks out towards the rear of the drawout carriage, keeping the wires attached to the auxiliary switch blocks. 4. Once the auxiliary switch blocks and attached wiring are accessible, mark the wires and note the relationship between each wire and its associated auxiliary switch terminal. Remove the wires from the auxiliary switch block. 5. Reinstall the wires to the new switch block. Note that the lower auxiliary switch block (10.2) differs from the upper auxiliary switch block (10.1).

22

10.2

1 . . . . . .Contactor Housing 3 . . . . . .Actuator Arm Bolt 7 . . . . . .Actuator Arm 10.1 . . .Upper Auxiliary Switch Block 10.2 . . .Lower Auxiliary Switch Block

Figure 16. Auxiliary Switch Block Replacement

Maintenance 11. (Electrical trials) Apply control power and switch the contactor to the closed (ON) position. The contactor should close correctly and without unusual hesitation. Verify that the contactor opens when the control power is removed. Using auxiliary contacts which are not connected to control power, verify that auxiliary contacts (NO) which are to be closed when the contactor is closed are closed. Similarly, these contacts should be open when the contactor is open. Similarly verify that NC contacts are closed when the contactor is open, and are open when the contactor is closed. Operate the contactor approximately 20 times, and then reverify auxiliary contact condition.

Hazardous voltage. Will cause death, serious injury, or property damage. Always de-energize and ground the equipment before performing maintenance.

Electronic Economizer Replacement To replace the electronic economizer assembly, remove the drawout contactor carriage from the controller enclosure, and disconnect all sources of power. For non-drawout type contactors, disconnect and ground all sources of power, and (if needed) remove the contactor from the enclosure. The replacement procedure is as follows (refer to Figure 17): 1. Disconnect the magnet coil (8.1) from the terminals of the electronic economizer. 2. Remove the screw (11.2) which secures the cover (11.1) to the electronic economizer assembly housing. 3. Cover (11.1) will be retained and reused. 4. Remove the screws (11.3) which secure the electronic economizer (11) in the housing, and remove the electronic economizer (11) from the housing. 5. Install the new electronic economizer in reverse sequence. 6. To continue the installation, the contactor must be closed. This requires application of control power to the main coil. Use appropriate precautions to avoid injury or shock when control power is applied to the contactor. 7. (Electrical trials) Apply control power and switch the contactor to the closed (ON) position. The contactor should close correctly and without unusual hesitation. Verify that the contactor opens when the control power is removed. Operate the contactor approximately 20 times to verify correct installation and operation.

23

Maintenance

1

SIEMENS

11.1

11.2

11

Figure 17. Electronic Economizer Replacement

24

11.3

8.1

1 . . . . . . . . .Contactor Housing 8..1 . . . . . . .Magnet Coils 11 . . . . . . . .Electronic Economizer 11.1 . . . . . . .Cover 11.2, 11.3 . .Screws

Maintenance After a Fault Inspection Hazardous voltages.

The following areas should be inspected after a fault has occurred.

Will cause death, serious injury, or property damage.

Enclosures

Disconnect, lockout, and ground incoming power and control voltage sources before beginning work on this or any other electrical equipment. Maintenance should be performed only by qualified personnel.

External evidence of enclosure deformation usually is indicative of damage within. Extensive damage will require replacement of the enclosure parts and the enclosed equipment. Insure that door mounted equipment and safety interlocks function properly. Verify that hinge and latch integrity is maintained.

Introduction Terminals and Internal Conductors Before performing any maintenance: • Test all power terminals to verify that incoming power has been disconnected. Use only approved high-voltage test equipment to check voltage on power terminals. Do not attempt to measure highvoltage (over 600 volts) with a volt-ohm meter. • Check all control and secondary circuit terminals with a voltmeter to make certain that all sources of incoming control and secondary voltage have been disconnected. • Connect safety grounds to power terminals after the system has been de-energized, and prior to working on the equipment. • Perform all disconnecting, grounding, and lockout operations in accordance with established safety procedures. • Follow the procedure outlined in the PreEnergization Check section of this manual before power is restored.

General The excessive currents occurring during a fault may result in structure, component and/or conductor damage due to mechanical distortion, thermal damage, metal deposits, or smoke. After a fault, repair the cause of the fault, inspect all equipment per NEMA Standards Publication No. ICS2 Annex A and make any necessary repairs or replacements prior to placing the equipment into service again. Be sure that all replacements (if any) are of the proper rating and are suitable for the application. If in doubt, consult your Siemens representative.

Replace all damaged parts which show evidence of discoloration, melting or arcing damage. Special attention should be paid to the stab (disconnect) fingers. Overload Relays The complete overload relay must be replaced if burnout of the heater element has occurred. Any indication of an arc striking or burning the overload relay also requires replacement of the relay. If there is no visual indication of damage that would require replacement, contact operation must be verified by electrically or mechanically tripping and resetting the overload relay. Fuse Holders Replace fuse holders if the insulation mounts, barriers, or fuse clips show signs of damage, deterioration, heating, distortion or looseness. Fuses Always replace all three fuses in a three phase circuit even though only one or two are open circuited since internal damage suffered by fuses not replaced could result in nuisance shut-down later. Perform the “PreEnergization Check” procedures detailed in the Installation section of this manual before restoring the equipment to service.

25

Troubleshooting In the event that operating problems are encountered, use the troubleshooting chart to isolate the cause of the malfunction and find the remedy. If the corrective action given in the chart fails to correct the difficulty, consult your Siemens representative.

Hazardous voltages.

The following information is required if it is necessary to contact Siemens relative to the equipment.

Disconnect and lockout all power supplying this equipment except where low-voltage control power is required prior to making these checks and exercise extreme caution at all times.

1. Siemens serial number (and part number, if available). 2. Nameplate data on contactor. 3. Duty cycle and any details of operation. 4. Length of time in service and approximate total number of operations. 5. Voltage, current and frequency. 6. Description of problem. 7. Any other pertinent information concerning the problem.

26

Will cause death, serious injury, or property damage.

Troubleshooting Table 11.Troubleshooting Phenomenon

Possible Causes

Will not Does Not Open Overheated Overheated close (Latch Type) Trip Coil Main Coil

• • • • • • • •

• • • • • •





Latch Is Not Survey main circuit without voltage Engaged Remove all power before inspecting

• • • • •







• •

• • •

• •

Corrective Action If inspection and/or corrective action is difficult, inform Siemens immediately

Control power supply voltage is too low

Decrease the voltage drop to increase the voltage to 90% or more of the rating.

Difference in control voltage

Proper rating

Defective control circuit

Check connection diagram

Poor connection and/or loose screw

Ensure that the connection is tight

Bad control switch contact

Clean if contact resistance is too high. Replace if necessary.

Wrong terminal connection

Connect correctly

Blown power supply fuse

Remove cause of fault and replace

Disconnected coil

Determine cause and correct

Faulty electronic economizer or magnet coils

Check the coil current. Replace electronic economizer or magnet coils as needed

Incorrect latch mechanism operation

Energize latch coil and inspect latch hook

Mechanism jammed

Lubricate corresponding portion or remove cause of jam

Defective auxiliary switch block

Clean or replace

Faulty auxiliary contact

Clean or replace

27

28

Figure 18. 96H35 or 97H35 Vacuum Contactor (5kV)

9

15

13

26

31

37, 36

4

13

30

2

Front View

3

Vacuum Contactor

16

34

2

1

13

10

32

33

11

27A (96H3) 39 3

41 13

38

11

16

26

8

24

R.H. Side View (96H3)

14

6 12

6 12

21

19, 20

28, 29, 30

25 22

25

27B (97H3) 13 3

41

11

16

37 36 31, 32, 33 24

1, 2

R.H. Side View (97H3)

40 7B (97H3)

Vacuum Contactor

Fuse Holder Required with 2-barrel Fuse Only

Control Wire Harness

Transformer Leads

40 7A (96H3)

Vacuum Contactor

1, 2

23

37 36 31, 32, 33

L.H. Side View

18 17

Fuse Holder Required with 2-barrel Fuse Only 5A (96H3) 5B (97H3)

7A (96H3) 7B (97H3)

43 (97H3)

Rear View

1 42

35

CPT

29

28

25 (Bø Only)

14

25 22

6 12

21

19, 20

28, 29, 30

6 12 25

Parts

Parts Table 12. Type 96H35 or 97H35 (5kV) Contactor (Refer to Figure 18)

*

Contactor Quantities Drawout Stationary

Item

Description

Part Number

1 2

LH Side Rail RH. Side Rail

25-154-488-560 25-154-488-559

1 1

– –

3 4

Contactor Mtg. Tray LH Side Plate

25-154-521-554 25-154-488-571

1 1

– –

5A 5B 6 7A 7B 8

RH Side Plate RH Side Plate Insulator Molding CPT Mounting Plate CPT Mounting Plate CPT Fuse Block

25-154-488-572 25-154-488-598 25-407-783-005 25-154-488-566 25-154-488-595 25-154-247-061

1 (96H3 Only) 1 (97H3 Only) 2 1 (96H3 Only) 1 (97H3 Only) 1

– – – – – –

9 10

Wheel Wheel Shaft

18-658-134-345 25-154-301-034

4 3

– –

11 12

Insulator Molding Copper Spacer

25-407-783-001 25-131-570-001

1 6

– –

13 14

Side Support LSI Mounting Bracket

25-154-488-007 25-154-488-552

2 1

– –

15 16

Wheel Shaft LH Front Interphase Barrier

25-154-488-051 25-154-488-081

1 2

– –

17 18

#8 GA - 7.2kV Cable #8 GA - 7.2kV Cable

25-154-288-503 25-154-288-504

1 1

– –

19 20

LSI Finger LSI Support

Consult Factory Consult Factory

1 1

– –

21 22

Finger Assembly Line Finger Assembly Load

25-131-570-527 25-131-570-583

3 3

– –

23 24

CPT Fuse Clip Fuse Clip Assembly Rear

25-127-244-001 25-154-515-509

4 1

– –

25 26

Boot for Finger Terminal Block Bracket

25-154-488-055 25-154-488-008

2 1

– –

27A 27B 28

Interlock Cable Assembly Interlock Lever Copper Bar A Phase

25-213-200-843 25-213-200-508 25-154-488-268

1 (96H3 Only) 1 (97H3 Only) 1

– – –

29 30

Copper Bar B Phase Copper Bar C Phase

25-154-488-269 25-154-488-270

1 1

– –

31 32

Copper Bar A Phase Copper Bar B Phase

25-154-488-266 25-154-488-001

1 1

– –

33 34

Copper Bar C Phase Contactor Mtg. Angle RH

25-154-488-267 25-154-521-552

1 1

– –

35 36

Contactor Mtg. Angle LH Fuse Clip Inner

25-154-521-553 25-135-228-058

1 3

– –

37 38

Fuse Clip Outer Vacuum Interrupter Kit

25-135-228-059 25-154-654-001*

3 1

– –

39 40

Closing Coil Assembly Kit Aux. Block (Bottom)

25-154-654-002 25-154-158-006

1 1

1 1

41 42

Aux. Block (Top) Electronic Economizer

25-154-654-004 25-154-654-003

1 1

1 1

43

Cover Plate

25-154-488-128

1 (97H3 Only)



Kit 25-154-654-001 for 3TL8 contactor serial number 31670936 and higher. For 3TL8 contactor serial number up to 31670935, use kit 25-154-654-005.

29

30

Figure 19. 96H37 or 97H37 Vacuum Contactor (7.2kV with 18R-24R Fuses)

9

15

13

26

31

37, 36

4

13

30

2

Front View

3

Vacuum Contactor

16

34

2

1

13

10

32

33

11

27A (96H3) 39 3

41 13

38

11

16

26

8

24

R.H. Side View (96H3)

14

6 12

6 12

21

19, 20

28, 29, 30

25 22

25

27B (97H3) 13 3

41

11

16

37 36 31, 32, 33 24

1, 2

R.H. Side View (97H3)

40 7B (97H3)

Vacuum Contactor

Fuse Holder Required with 2-barrel Fuse Only

Control Wire Harness

Transformer Leads

40 7A (96H3)

Vacuum Contactor

1, 2

23

37 36 31, 32, 33

L.H. Side View

18 17

Fuse Holder Required with 2-barrel Fuse Only 5A (96H3) 5B (97H3)

7A (96H3) 7B (97H3)

43 (97H3)

Rear View

1 42

35

CPT

29

28

25 (Bø Only)

14

25 22

6 12

21

19, 20

28, 29, 30

6 12 25

Parts

Parts Table 13. Type 96H37 or 97H37 (7.2kV) Contactor 18R - 24R Fuses (Refer to Figure 19)

*

Contactor Quantities Drawout Stationary

Item

Description

Part Number

1 2

LH Side Rail RH. Side Rail

25-154-488-560 25-154-488-559

1 1

– –

3 4

Contactor Mtg. Tray LH Side Plate

25-154-521-554 25-154-488-571

1 1

– –

5A 5B 6 7A 7B 8

RH Side Plate RH Side Plate Insulator Molding CPT Mounting Plate CPT Mounting Plate CPT Fuse Block

25-154-488-572 25-154-488-598 25-407-783-005 25-154-488-566 25-154-488-595 25-154-247-061

1 (96H3 Only) 1 (97H3 Only) 2 1 (96H3 Only) 1 (97H3 Only) 1

– – – – – –

9 10

Wheel Wheel Shaft

18-658-134-345 25-154-301-034

4 3

– –

11 12

Insulator Molding Copper Spacer

25-407-783-001 25-131-570-001

2 6

– –

13 14

Side Support LSI Mounting Bracket

25-154-488-007 25-154-488-552

2 1

– –

15 16

Wheel Shaft LH Front Interphase Barrier

25-154-488-051 25-154-488-081

1 2

– –

17 18

#8 GA - 7.2kV Cable #8 GA - 7.2kV Cable

25-154-288-503 25-154-288-504

1 1

– –

19 20

LSI Finger LSI Support

Consult Factory Consult Factory

1 1

– –

21 22

Finger Assembly Line Finger Assembly Load

25-131-570-527 25-131-570-583

3 3

– –

23 24

CPT Fuse Clip Copper Bar

25-127-244-001 25-154-515-509

4 3

– –

25 26

Boot for Finger Terminal Block Bracket

25-154-488-055 25-154-488-008

2 1

– –

27A 27B 28

Interlock Cable Assembly Interlock Lever Copper Bar A Phase

25-213-200-843 25-213-200-508 25-154-521-549

1 (96H3 Only) 1 (97H3 Only) 1

– – –

29 30

Copper Bar B Phase Copper Bar C Phase

25-154-521-550 25-154-521-551

1 1

– –

31 32

Copper Bar A Phase Copper Bar B Phase

25-154-515-520 25-154-515-521

1 1

– –

33 34

Copper Bar C Phase Contactor Mtg. Angle RH

25-154-515-522 25-154-521-552

1 1

– –

35 36 37

Contactor Mtg. Angle LH Fuse Clip Inner Fuse Clip Outer

25-154-521-553 25-135-228-058 25-135-228-059

1 3 3

– – –

38 39

Vacuum Interrupter Kit Closing Coil Assembly Kit

25-154-654-001* 25-154-654-002

1 1

– –

40 41

Aux. Block (Bottom) Aux. Block (Top)

25-154-158-006 25-154-654-004

1 1

1 1

42 43

Electronic Economizer Cover Plate

25-154-654-003 25-154-488-128

1 1 (97H3 Only)

1 –

Kit 25-154-654-001 for 3TL8 contactor serial number 31670936 and higher. For 3TL8 contactor serial number up to 31670935, use kit 25-154-654-005.

31

32

Figure 20. 96H37 or 97H37 Vacuum Contactor (7.2kV with 2R-12R Fuses)

9

15

13

26

31

4

13

30

36, 37

Front View

13

29

28

2

10

32

33

11

39 3

27A (96H3)

41 13

38

24 11

16

5A (93H3) 5B (94H3)

34 1 7A (96H3) 7B (97H3)

3

Vacuum Contactor

16

Rear View

43 (97H3)

1 42

2 35

CPT

25 (Bø Only)

26

8

23

40 7A (96H3)

36

6 12

6 12 25 22

21

28, 29, 30

25

Control Wire Harness

Transformer Leads

R.H. Side View (96H3)

1, 2

Vacuum Contactor

31, 32, 33

L.H. Side View

18 17

27B (97H3) 13 3

41

24 11

16

40 7B (97H3)

R.H. Side View (97H3)

1, 2

Vacuum Contactor

31, 32, 33

14

12 25 22

6

21

19, 20

28, 29, 30

6 12 25

Parts

Parts Table 14.Type 96H37 or 97H37 (7.2kV) Contactor 2R - 12R Fuses (Refer to Figure 20)

*

Contactor Quantities Drawout Stationary

Item

Description

Part Number

1 2

LH Side Rail RH. Side Rail

25-154-488-560 25-154-488-559

1 1

– –

3 4

Contactor Mtg. Tray LH Side Plate

25-154-521-554 25-154-488-587

1 1

– –

5A 5B 6 7A 7B 8

RH Side Plate RH Side Plate Insulator Molding CPT Mounting Plate CPT Mounting Plate CPT Fuse Block

25-154-488-557 25-154-488-598 25-407-783-005 25-154-488-566 25-154-488-595 25-154-247-061

1 (96H3 Only) 1 (97H3 Only) 2 1 (96H3 Only) 1 (97H3 Only) 1

– – – – – –

9 10

Wheel Wheel Shaft

18-658-134-345 25-154-301-034

4 3

– –

11 12

Insulator Molding Copper Spacer

25-407-783-001 25-131-570-001

1 6

– –

13 14

Side Support LSI Mounting Bracket

25-154-488-007 25-154-488-552

2 1

– –

15 16

Wheel Shaft LH Front Interphase Barrier

25-154-488-051 25-154-488-010

1 2

– –

17 18

#8 GA - 7.2kV Cable #8 GA - 7.2kV Cable

25-154-288-503 25-154-288-504

1 1

– –

19 20

LSI Finger LSI Support

Consult Factory Consult Factory

1 1

– –

21 22

Finger Assembly Line Finger Assembly Load

25-131-570-527 25-131-570-583

3 3

– –

23 24

CPT Fuse Clip Fuse Clip Assembly Rear

25-127-244-001 25-135-186-517

4 1

– –

25 26

Boot for Finger Terminal Block Bracket

25-154-488-055 25-154-488-008

2 1

– –

27A 27B 28

Interlock Cable Assembly Interlock Lever Copper Bar A Phase

25-213-200-843 25-213-200-508 25-154-521-549

1 (96H3 Only) 1 (97H3 Only) 1

– – –

29 30

Copper Bar B Phase Copper Bar C Phase

25-154-521-550 25-154-521-551

1 1

– –

31 32

Copper Bar A Phase Copper Bar B Phase

25-154-488-266 25-154-488-001

1 1

– –

33 34

Copper Bar C Phase Contactor Mtg. Angle RH

25-154-488-267 25-154-521-552

1 1

– –

35

Contactor Mtg. Angle LH

25-154-521-553

1



36 37

Fuse Clip Inner Fuse Clip Outer

25-135-228-058 25-135-228-059

3 3

38 39

Vacuum Interrupter Kit Closing Coil Assembly Kit

25-154-654-001* 25-154-654-002

1 1

1 1

40 41

Aux. Block (Bottom) Aux. Block (Top)

25-154-158-006 25-154-654-004

1 1

1 1

42 43

Electronic Economizer Cover Plate

25-154-654-003 25-154-488-128

1 1 (97H3 Only)

1 –

Kit 25-154-654-001 for 3TL8 contactor serial number 31670936 and higher. For 3TL8 contactor serial number up to 31670935, use kit 25-154-654-005.

33

All statements, technical information and recommendations contained herein are based on information and tests we believe to be reliable. The accuracy or completeness hereof is not guaranteed. Since conditions of use are outside our control, the user should determine the suitability of the product for its intended use and assumes all risk and liability whatsoever in connection herewith.

Siemens Power Transmission & Distribution, Inc. 7000 Siemens Road Wendell, NC 27591 phone: 1-800-347-6659 © 2008, Siemens Power Transmission & Distribution, Inc. All rights reserved. E50001-U229-A304-X-US00 (replaces SGIM-9088D) (08-2008) Subject to change without notice.

www.usa.siemens.com/energy

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